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2 SheetsSheet 1.

T. J. GHUBB. APPARATUS AND PROCESS FOR MAKING STEEL. 'No. 79,313.

Patented June 30, 1868.

2 Sheets-.Sheet 2. J. OHUBB.

APPARATUS AND PROCESS FOR MAKING STEEL. No. 79,313.

Patented June 30, 186

N am: PETERS co. PucTaumoA wAsnmcToN. 0 cv gnitsh gist gaunt @fi'icci Letters Patent No. 75,313, dated June 30,1868; untedated December 30, 18(5T.

IMPROVEMENT IN APPARATUS AND PEOGBSSES FQB MAKING STEEL.

dlgtfiriuhnl: more: is in ilgm'fiztms Went mm maiiing'pprt if the sums TO ALL WHOM IT- MAY CONCERN! 7 Be it known that I, THOMAS 'J. CBUBB, of- Willin'mshnrg, in tho county of Kings, and State of New York, have'inve'nted new Improvements in Furnaces for Making and Melting Steel and other Metals ond I do; hereby declare the following to be a full, clean and exact description thereeflrefereniie being bad to the accompanying drawings, making part of. this specification, 'in which-- Figure 1 represents 'a vertical longitudinal section of u furnace with its severalconnections, including dcsnlphnrizing, deo'xidizing', earboniziug, and melting-chambers.

Figure 2 is an end view of the same.

Figure 3, sheet 1, is one of the fire-shields and shimmers S, shown in figs. l, 2, 5, and 6.

Figure 4, sheet 1, is one of the arch-bricks T, shown in figs. '1 and 2, also in figs. 5 and 6.

Figure 5, sheet 2, is a modification ofj the furnace, being a vertical longitndinal section, showing on air and 'gasdieating apparatus or regenerative-furnace! booting the samo attached thereto.

' .Figure 6, sheet 2, is a sectional end view of fig. 5. Similar letters ofrefcrence in-all the figures indicate corresponding parts.

My invention consistsi In theconstru'ction of series of deoxidiziug and carbonizing-netorts or.chambers, arranged so as to prevent the gases from the (heat-producing) fuelfrom comingjn contact with the ore in combination with and so as to discharge the ore into a melting-chamber while in a highlyheated state.

I n the arrangement of a melting-chamber with openings and doors or gates at both ends, so as to .t'acilitate the manipulation of the ore or metal under treatment from hothends.

In making provision for feeding the ore or'metal stone and of the furnace, and tapping the molten metal at the other end H k vIn making provision for conducting heated air and gases of the fuel over the.ore and molten metal, said gases entering at one side or end of the said furnace or melting-chamber, and passing out at the sides or other end. In making provision for shielding tho-ore and molten metal from the direct action of the gases of the fuel" by arches fl.- i

In maliing provision for shielding and protecting the molten metal in the melting-chamber B, from the direct or chemical action of the air-flame or gases of the fuel, by the floating shields S.

In making provision for skimming ofi the surfnce of the molten metal by the floating skimmer: S. 1

In arranging a chain or series of shields or scrapers or shimmers, S S S, fed-in. at one part of the furnace, and passing out at some other part thereof, thus producing a separation of the lighter' portion of the molten mass from the heavier or lower strata, removing the upper, or lighter strata to another part of or out of the melting-chambers or furnace entirely.

In the construction of a vessel or melting-chamber of a furnace, so arranged as to he snfliciently heated solely from above, when the metaland substances therein shall all be brought in't o a molten or liquid state pro ricus too-skimming, tapping, and drawing of the metal.

In the making provision for and melting o'i'met'al by heat applied solellv from above the metal, in combina tion with a gas-regenerative apparatus-or furnace.

'In the arrangement of a furnace or a vessel or vessels in a furnace for the melting of metals, in combination \rith and heated by the flame produced by the mingling together of thc air and gas arising from and having passed through an air-heating and gas-heating or reheating furnace, chamber, or apparatus in separate currents.

In providing for keeping thennder side of the melting-chamber cool, or from melting or leaking, by the arrangement of an air-chamber or space, C, below the same.

The ore having been mixed with carbonates oriother. deoxidiziiig and carbonizing-matter, is fed into the upper ends of the retorts AA A, and the heat applied to the outside ofthe said rctorts a auflicient length of time to thoroughly deexidise all the ore, and enrboniae it to the degree required.

The oarburetted ore is raked down through openings dyfigs. 2 and 5, falling into the melting-chamber 13'. It is then pushed forward to fill the space bencatlrtbc arch ,T, and then the gas andnir or flame are turned on,

and made to flow over the ore or metal. When the ore inlthis chamber-13mins melted down, another charge is,

supplied from the retorts, until the chambers]! 13 shall have become so fdll of molten matter as that any scum or cindcr that mayhave formed upon the metal shall run out at the upper end E; Then more shimmers rnhy ,be fed in at the lower end, through the doorway or opening H in the end of the chamber B, pushing the floats back, and adding more floatingshields or scraping shimmer, untilsomc of them pass out at the upper; or other end E of the chamber B, and scrape out with them the upper strata or the cinder or scum upon the metal,

thus separating the pure metal from the impurities. When the molten metal has been properly skimmed oif and otherwise manipulated, and heated to the proper, degree of heat, it may be topped and discharged at the opening 9 into heated moulds or otherwise. A part of the molten metal should remain in the inciting-chamber to assist in reducing the next charge. The operation should be continuous.

The heat to this furnace may be applied from any source. I prefer to-lieat the furnace by an air and gasbeatingupparatus pr furnace, by which a steady, high degree of host may be obtained, without any injurious blast.

When melting of new or old bar, pig, or scrap metol,'Ip:'-cfer to'have them in as small particles as convenient.

Small particles of metal may be fed into the uppcr'retorts, or they may he fed-into the furnace or meltingchambers B at opening E.- Any chemicals may also be fed in .with the ore or metal or metallic substances at the upper retorts, or at the openings E or H. The arch-brioke T may be used or not, at the option of the manipulator, or they may be readily. taken out or replaced while the heat is on, or while the furnace is' in full operation, or when destroyed bylire or otherwise, they may be replaced readily.

Tho firc'sbields may be used or not, as thcy may be removed readily to allow the chemical action of the heated gas or gases, orhcaterl or cold air to act chemically or otherwise upon the metal or other substances under treatment. Gas or gases rising from heated rosin, tar, coal-tar, coal or rock-oil, petroleum, or any carbonaceous matter, or chemical substances in the form of gas or vapors, may be, thus passed over thc molten metal, or brought in direct contact with the metals or oro beneath the arch T, or shields S, by removing the same at any time or during any part of the operation, or replaced, and such chemical action or actions discontinued at any time or part of the process.

The action of the heated sir',,gas or gases, may be regulated by valves, gates, or dampers outside the furnace. It is not essential that the upper retorts should be directly over the melting-chamber, or heated by the some.

means as is applied tothe melting-chamber.

The arch-pieces T may be of an uneven surface on one or both sides, being ribbed, grooved, corrugated, or with hollows and projections, of any shape upon their surface, so'as to give increascd'heat, absorbing, and conducting power from the outer or upper side tothe lower or inside, and the lower or inside may also have projections, so as to conduct or radiate a greater amount of-lieat to the metal or material beneath it, than a plain surface would do. I prefer" making them co'rrugatedpso as to give both extended surface and increased strength, and at the same time securing a thin heat-conductingshield. The shield and scrapers S may also be of such shape as to secure all the advantages of a. light floating scraper with many scraping surfaces, 0. thin good conductor of the heat to the metal beneath it, and an oatensive heat-absorbing'surface'on top, thus bringing the metal in close contact with the flame or fire, Without'burning orfl exposing it to the direct action thereof, upon a principle that may be spread out to-a large or extended surface, melting a large quantity of metal at one time, without the neccsity of conducting the heat thereto through thick walls or. expensive crucibles.

Several kinds-of iron ores may be mixed with each other, such as oxides with carbonates, or iron'oro with ores of other metals, such as manganese, titanium, or arith carbon in any form, suchas oil, rosin, tar, coal, coke, or charcoal, or with any other substauce,-or any proportions of each, according. to the kind of ore or metal required, and thus fed into the upper ends of the retorts A A A, or into the chamber B direct, or the. furnace or melting-chamber B may first be charged with pig or cast iron, and with the oxide of iron ore, or

natured or partly natured iron, or with wrought iron or semi-steel, or the ore, when reduced and melted, may

be charged with Frankenite iron, and wrought iron, or any highly-carbonized iron or ore, or with any other metal, such as manganese, titanium, or the ores thereof, or carbon or any other substance may be added at either end of the chamber B. I

In fact this furnace is capable of converting, cementing, reducing, melting, and refining most any kind of ores, metals, or alloys thereof.

By the terin cast steel, I mean iron-combined with carbon and other substances, in such proportions or to such a degree that it will be crystallized, and'yetbe ductile or malleable, or hard andbrittle, in accordance with the quantity of carbon and other substances combined with the iron, variable at the will of the monufacturer. It is cast steel so long as the molten metal can be run or cast intcra'mould. Iron talron out of a furnace, congealed in the form of a boiler a bloom, and squeezed, hammered, or rolled into solid metal, is not cast steel. fiy the term pig-iron, I mean any crude'or cast iron, or iron containing a surplus of carbon, oxygen, and some silicates and impurities. By natured iron, I mean iron ore deprived of most of its carbon and impurities. By the term blister steel, is meant iron bars converted by the 'cementation process. Highly-carbonized ore is iron ore converted by a similar process, or found as a native carbonate of iron Wroughtiron is bar or new or old scrap-iron. Cast iron should be considered as a partly-refined pig-iron, and usually contains less carbon, although some qualities of pig-iron and old or oew cast scrap-iron are all designated us oast iron.

7 Highly-carbonized iron is iron in any form combined with a large portion of carbon. I

The heat or the heated air and gas may be applied from either end or side of the mclting-chamber B B, or the part of the melting-chamber B. where the ore or metal is melted, or, where the igneous fusion first takes place, may be heated by separate means from the part of the chamber B where the metal is all in a fluid state.

The general arrangement of this furnace, or the several depnrtmchts or'parts thereof, may bo'vuried with. out departing from the general principle of the invention, that is to-soy, so league the orcs or metals are fed into the furnace at one part and tapped or run out at npothcr part, the scum or impurities continually pushed back fr m the trip-hole, thus producing a continuous refining process, as the quality of-the material in the furnace is richer in pure steel as it nears the tap-hole end or part of the melting-chamber or furnace, and all the impuritics arciloodcd or scraped back and out at the opposite 'side'or end. I

The floating shield-pieces may be made of platina, if desired, or thc arch-picccs, T, and shield and scraperpieces, S, may all be made in short lengths, and moulded out of fire-clay, pluinbngg or other refractory substance, and the material composing the parts of th furnace exposed to high heat shouldbe made of fire-clay. The lining of the melting-chamber may be made of fire-clay, soapstone, or other refractory substance.

Having described my improvements, and their application to the process and furnaces patented by me, May 21, 1867,.Ne. sheer. and June 4, 1861;; o-'65.r'.

1. The construction of a series of deoiridizing'snd carbonizing-retorts or chambers, A A A, arranged so as to prevent the gases from the hcat producing fuel from coming in contact with the ore or the materials in the retort, in combination with a melting-chamber for the purposes set forth.

2. The arrangcincnt'of themelting-chamber B B with opening sand doors at both ends, insuch a manner as to facilitate the manipulation of,thc ore ormctal under treatment from both ends, substantially as described.

3. Making provision for feeding looseorejand metallic and other substances in at one end of the meltingchamber or furnace B, and tappingtlie molten metal at the other end, substantially as described.

4. Making provision for conducting heated air and gases over the ore or molten metal, said air and gases entering at one side or end of the said melting-chamber or furnace, and paiisipg out at the sides or other end thereof, for'lihe purpose of reducing said ore, metal, or metallic substances therein into a liquid or molten mass, substantially as described, n v x 5. Making provision for shielding the ore, metal, and other substances from'the direct action of the gases of the fuel by arches T.

6. Making provision for shielding and protecting the molten metal in a melting-chamber from the direct action of the air, dime, and gases of the fuel by floating-shields, or an equivalent refractory substance or substances floating on the top of the metal, as described.

7. Melting provision for skimming oh" the surface of molten metnlby floating scrapers, or their equivalent, substantially as'described. v

8. Efi'ecting a separation ofthe cinder or upper luycr of substances flouting on mojten metal by the means herein specified and described.

9. The construction of a vessel or melting-chamber of a furnace, so arranged as it may be sulliciently heated solely from above, by which means the metal therein becomes fully melted into a liquid state previous to skimming, tapping, and drawing off the same, substantially as herein described.

10. Making provisions for and effecting the melting of vmetals by heat applied solely from above' the metal, when said heat is derived from a gas-regenerative apparatus or furnace.

11. The arrangement of a furnaceor of. a vessel or vessels in a furnace for melting metals therein, in combination with and heated-by the flamdprodueed by the mingling together of the air and gas rising from und'having passed through an air-heating and gss heating or reheatingfurnace, chamber, or apparatus in senarute currents.

12.-Providing for keeping the under side of the melting-chamber, or chambers in which the melting-chamber or vessel is placed,ccol, or from melting or leaking by the arrangement of a cold-air chamber or space below the same, C.

13. The employment of slabs o'r arch-pieces T T, for the purpose setforth.

14. The employment of scrapers or shimmers S S, or their equivalent, for the purpose set forth.

15. The employment of floating fire-shields and'hc'at-conduetors S S, or their equivalents, for the purpose set forth. g

16, Constructing slabs, arches, and shieldswith'an uneven or irregular surface on one or both sides thereof, for the purpose set forth. I I

17. The method or proeessof refining metals, and separating the dross and other extraneous matter from the surface of melted metal by mechanicalpowcr and appliances, or of inserting of refractive or infusible colder substances than the dress and scum, cooling und congealing them that they may be skimmed or removed from oil' the surface of the molten metal, substantially as set forth.

18. Making provisions in the construction of e melting-chamber ofa furnace forredueing iron into such a liquid state by igneous fusion, that highly-carbonized iron ore, or pig-iron; cast iron, or steel, and natured iron ore, or wrought-iron may fuse and mix 'with each other, and that the impurities and surplus carbon, silicon, and other matter that is not essential to the production of good cast steel,may be flooded and removed from the surface of the molten steel, refining and running the same intovcsscls or moulds, substantially as described.

19. Qbtnini-ng cast steel or products of any degree of mallenbility or ductility by melting together, in o,- vessel or chamber in a furnace, combinations of pigiron and. wrought iron, or of natured or partly-natured iron and cast iron, and fusing, mixing, refining, and running the same into moulds, substantially as described.

20. The production of cast steel by melting together, in a fixed or. stationary melting-vessel, chamber. or. furnace, cast iron and iron ore, when such iron ore has been previously reduced, or natured, or partly natured, or carbonized in-a separate vessel, retort, or furnace, and when mixed with manganese or titanium, or the ores or compounds thereof, and fusing, mixing, and running tiresome into moulds.

21; The production of cast steel by firatmelfing the iron or metal containing the most carbon 'in a. stationary vessel, and adding the metal or ore'contoining-ihe least carbon to the molten mom]. and, when the nholo' is reduced to the proper consistency of cast ateel, 1'nnning the some into'moulds.

22. Efiecting a continuous process of nducing or melting and refining ores and metal by mechanical appliances, and at one heating, and in one furnacemhambcr, substantially as described'.

23. Efl'ecting a continuous process of making cast steel from iron ore by sfibm'erging it into a hath of molten cast iron, or highly carbonized iron, whereby the'whole will be liquefied and brought, to the 'eonsfszoncy of one:

steel, and refined and run into :honldn.

EH03; J. CHUZBB.

Witnesses:

F'nnnnmox Srncnzc, J0EE Fmmn. 

